Packaged popcorn kernels and popping oil



Aug. 11, 1953 J. T. MARTIN 2,648,610

PACKAGED POPCORN KERNELS AND POPPING OIL Filed May 8, 1951 asf! M GMW Patented Aug. 11, 1953 PACKAGED POPCORN KERNELS AND POPPING OIL Joseph T. Martin, Thomasville, Ga., assignor, by mesne assignments, to Rose Kist Foods, Inc., Thomasville, Ga., a corporation of Georgia Application May 8, 1951, Serial No. 225,201

4 Claims. l

The present invention relates to a new methd of packaging popcorn kernels and to the resulting product; to a new edible popping oil and to the method of making the same; and to apparatus for use in packaging the popcorn kernels and popping oil.

More particularly, the invention relates to the packaging of popcorn kernels in such form that they are ready to be poured into a corn popper, without requiring the user to do any measuring of either kernels or oil, as is now the customary practice. In other words, the packaged product contains the proper amount of popcorn kernels and popping oil for best popping results.

The principal object of the invention is to provide a package containing popcorn kernels and popping oil in a ready-to-pop condition.

Another object of the invention is to provide a method of packaging popcorn kernels in such a way as to retain the proper moisture content in the kernels and at the same time utilize the moisture-retaining medium to effect popping of the kernels to maximum size or volume.

Another object of the invention is to provide packaged raw popcorn which will have a long shelf life.

Another object of the invention is to provide an edible blend of vegetable oils which will prevent the escape of moisture from the popcorn kernels, but which will not penetrate the hull of the kernels and permeate the interior of the kernels.

Still another object of the invention is to provide a method of packaging popcorn kernels wherein the kernels are coated with and immersed in the proper amount of oil for effecting maximum popping volume of the kernels.

Still another object of the invention is to provide suitable apparatus for adding a predetermined amount of popping oil to a predetermined amount of popcorn kernels in a container.

A further object of the invention is to provide packaged popcorn kernels in which the kernels are of predetermined size so that the voids between the kernels when filled with oil will suflice as a measure of the proper amount of oil necessary for optimum popping of the popcorn.

A further object of the invention is to provide ready-to-pop ,packaged popcorn kernels characterized by the feature that the popcorn and popping oil can be simultaneously poured from provide a package of treated popcorn kernels from which any desired portion can be removed and used, without requiring resealing of the container, and Without danger of undue deterioration of the remainder of the popcorn kernels.

A still further object of the invention is to provide an edible popping oil and method of preparing the same which will provide for maximum popping volume and good taste and at the same time have a long shelf life without becoming rancid. l

Other objects and features of the invention will become apparent from the following description taken in conjunction with the accompanying drawings in which:

Fig. 1 is a diagrammatic View illustrating a glass container positioned to receive a predetermined weight or volume of popcorn kernels from a conventional weigher or bulk feeder;

Fig. 2 is a diagrammatic view illustrating the container after having been filled with popcorn kernels and in position to have the popping oil injected thereinto;

Fig. 3 is an enlarged detail view partly in crosssection and particularly illustrating a retainer plate for preventing the popcorn kernels from being displaced from the container while the popping oil is being forced thereinto; and

Fig. 4 is a view partly in cross-section of the filled container after capping and sealing.

In practicing the principles of the present invention, the popcorn is shelled and cleaned by conventional means to remove dirt and other foreign matter therefrom, and is then passed over a series of screens of predetermined mesh size in order to'select the kernel size best suited for packaging for the general consumer market. As one operative example of the invention, popcorn kernels are selected which will pass through a #20 conventional screen having an opening size of 2%4vof an -inch,`but which will remain upon a #13 conventional screen having an opening size of 1%4. ofan inch. The selected popcorn kernels are also l-passed over conventional gravityseparator screens whichwserveto separate the defective kernels, even though of proper size but of improper weight, from thesound kernels, so that only acceptable kernels Yare retained for packaging purposes. The selected popcorn kernels may be dried,-if necessary,v o r humidied, until they have a desired moisture content of `13.5% to 14.5%, and preferably 14%.

The popcorn kernels `may be packaged in con-v tainers of any suitable size, but ffor: household or domestic use, it is preferable to package .the

has been found experimentally that 3l/2 ounces f' of oil not only constitutes the correct amount for popping the ounces of popcorn kernels, but that such amount of oil when introduced into a 12-o`uce glass will substantially fill the voids between the popcorn kernels and provide a level such that all of the kernels are immersed f in the oil, and without having an excess layer of oil above the kernels. Thus, the' preferred ratio' of popcorn kernels to poppirig oil by weight is 10 to 31/2 or approximately 3 to 1. It is possible to package 10 ounces of popcorn kernels of a preselected size with 2% to 4 ounces of the popping oil in a suitable container and obtain fairly good results, although in order to obtain the best results and maximum popping volume and proper taste, it is preferred to mix only 31A.; ounces of oil with 10 ounces of popcorn kernels. An excessiveamount of oil will give the popcorn an undesirable oily taste and preclude its satisfactory use in making candied popcorn, and too little oil Will reduce the popping volume of the kernels.

The popping oil preferably used in packaging the popcorn kernels consists of a special blend of edible vegetable oils, comprising, by weight, 40% refined soy bean oil which has been hydrogenated and which has a melting point of about '78 F. to 80 F., 60% reiined peanut oil, and a sufficient amount of any suitable preservative to prevent rancidity. These two oils are preferably separately preheated, by steam or other suitable means, to a temperature of 160 F. to 190 F. and preferably to 180 F. and then introduced into a steam jacketed kettle (not shown) and mixed together bymechanical agitation while in the kettle and while maintained at a temperature or between 160 F. and 190 F. and preferably 180 F. The preservative is added to the kettle for uniform-dispersion in the oils. rlhe agitation is continued long enough to thoroughly mix or blend the oils and the period of agitation will vary, of course, with the volume of oils being mixed,v the size of the kettle and the type of mechanical agitator used. In any event, the time required for proper blending can be readily ascertained from working conditions and will present no problem to anyone familiar with the art.

Artificial butter flavoring and artificial coloring may be added, if desired, during the blending of the oils in the steam kettle. The butter flavoring may be added in the proportion of l2 c. c. per 100 pounds of blended oil, and artificial yellow, vegetable coloring may be added in the proportion of 1A; ounce of coloring per 100 pounds of the blended oil, more or less, depending upon the strength of color'desired. Any suitable preservative can be mixed with the oils to extend the shelf life of the product and prevent rancidity and, as an example, benzoate of Asoda in the amount of 116 of 1% by weight may be added to the oil.

The proportion of 40 pounds of hydrogenated soybean oil and 60 pounds of rened peanutoil is the preferred proportion, but fairly satisfac- 4 50% to 70% (50p-'70 pounds) refined peanut oil; Irrespective ofthe proportions of soy bean oil and peanut oil used within the ranges stated, the iavoring matter, coloring, and preservative may be added in the same proportion per 100 poundsvof themixed orblended oils.4 ,No salt is added to -the blended oils iin order'to avoid reaction with the oils and to avoid `possible development of rancidity.

The blended oils and preservative, either with or withoutl added flavoring and coloring matter, are taken from the steam kettle and introduced directly .into an homogenizer. The action of th agitator in the steam kettle thoroughly mixes together the two: oils and preservative (and the color and flavoring, if added) and the homogeniz'e ing prevents subsequent separation or agglomera-A tionofthe hydrogenated soy bean oil and elimiv nates the necessity of using an emulsifying agent; If' the homogenized oil is to be used directlyy in the packaging process then it is cooled. to a tem-s perature of about 120 F. by passing the same through a conventional heat exchanger. YIf the homogenized oil is not to be used immediately, then it can be stored in a suitable container. The homogenized oil can be sold in bulk to other processers, but if it is to be used for popcorn kernel packaging purposes, then it should bereheated to a temperature of about 120 F. to assure rapid flow into the voids between the pop.- corn kernels, as will appear more fully herein.- after. ThisV temperature is alsosuch Yas to en-l able the filled containers to be comfortably handled by the operator without fear .of burning the hands and at the same timel it vis also low enough to avoid breakage of the glass containers, as a result of undue temperature changes, .and the consequent waste of popcorn kernels and oil. The popping oil is somewhat viscous even at room temperatures and adheres toV the .popcorn kernels in completely surrounding relation there.- to, so that upon opening the container Vfor use, the popcorn kernels 'and the adhering. popping oil can be simultaneously'poured as a flowable mass into a suitable pan o1' popper. The un.-l used portion can be kept .in the container for a long period of time without 'airtight resealing, and without danger of rancidity developing.l

It is to be understood that While the homogenized blended oils have been described as a pope corn popping oil, the oil isnot limited to such use but is adapted for otherfuses such asfpreparing potato chips, French .fried potatoes, etc. Referring now to Fig. 1, a conventional weigher or bulk feeding apparatus is' generally identified by the reference numeralv l'land comprises. .a hopper? provided with a discharge'spout 3.." The bulk feeder I is adapted to discharge a predetermined weight or volume of popcorn kernels at room temperature into a container, such asa 12-ounce glass 4, which is vsuitable for popcorn packaging purposes intended for household consumer sales. The container '4 is supported by a platform 5 disposed below the'discharge spout '3. The bull: feeder I discharges a predetermined volumey of popcorn kernels'KsuiTicient to substantially completely ll v'thecontainer 4.: It has been determined experimentally'. thatapproximately 10 ounces of popcorn kernels lof 'the-size specified and with ythe desired moisture Acontent tory results can be obtained with rv30% toy 50% will substantially completely l'l the container '4.

While a container 4 in the form of -a -12'ounce glass has been referred to as suitablefor package ing purposes, the same is mentionedA by -wayg of illustration and notiimitauomandit 11s-tube distinctly understood that the principles ofthe The container 4v with the popcorn kernels therein is then manually or otherwise positioned upon a platform 6 slidably' mounted upon a vertical rod 1, said platform being adapted to be raised and lowered by any suitable mechanism. For illustrative purposes, a bracket 8 is shown fastened to the underside of the platform 6, 'and one end of a lever 9 is shown connected to the bracket 8 by a pivot pin II) riding Vin an elongated slot Il formed in one endof the lever 9. The other end of the lever 9 is fixed to a shaft I2 adapted to be oscillated by any suitable means (not shown). The platform Scarries an indexing ring I3 for properly indexing the container 4 with respect to a tube I4 having its upper end connected with the discharge outlet I5 of any suitable or conventional pump I6.

The pump I6 comprises a cylinder I'I, a piston therein, and a spring-pressed outlet check valve 2| mounted in the discharge outlet I5. The pump inlet I9 is connected by a pipe 22 with a tank 23 containing a supply of the preferred edible popping oil, described in detail hereinbefore. A piston rod 24 is connected at one end to the piston I8 and carries a roller 25 at its opposite end. A cam or eccentric 26 mounted upon a shaft 2'I is engaged with the roller 25 for effecting positive movement of the piston I8 in the cylinder I'I during the work stroke to force a predetermined volume of popping oil out of the cylinder `I'I, through the tube I4, and into the container 4. A spring 28 is disposed in the cylinder I'I and engaged with the piston I 8 for effecting movement of the piston in the opposite direction, as permitted by the cam 26. It is to be understood that the pump and operating mechanism therefore may be of any suitable construction, so long as it is adapted to pump a predetermined volume of oil into the container 4 on each work stroke of the piston I8.

The diameter of the cylinder I'I and the stroke of the piston I8 are proportioned,l according to one operative example of the invention, so that upon each intake stroke of the piston I8 a predetermined volume of the popping oil at a temperature of about 120 F., and equal to 31/2 ounces by weight, is drawn into the cylinder I1 through the inlet check valve 20, whereby, upon the work stroke of the piston I8, the oil is forced out of the cylinder II and into the tube I4 for rapid injection under pressure into the kernel-filled container 4.

The tube I4 is open at its lower end and provided with a plurality of openings 29 extending through the sidewall thereof in a region below a retainer plate 30 fixed by a set screw 3l to said tube at a predetermined distance from the discharge end of said tube. The plate 30 has a plurality of vent openings 32 extending therethrough which overlie the container 4 and permit air to escape from the container 4 as it is displaced by the popping oil being forced into said container while at the same time preventing the popcorn kernels K from being pushed out of the container by the pressure of the injected oil. The openings 32 are too small to permit the passage of the popcorn kernels K therethrough and the plate 30 thus makes it possible to quickly inject the oil into the container 4 and thereby greatly speed up the packaging process. The popping oil is, as before stated, preferably main- 7.', 6 tained ata temperature of about 120 F. inthe tank 23 to increase its viscosity so that it will flow freely through the tube I4 and into the voids in the container 4 between the kernels K.

It will be understood that the pump I6 is actuated in predetermined timed relation with the lever 9 so that the platform 6 is raised from its position shown in dot-and-dash lines in Fig. 2

- to its full line position, whereby the tube I4 enters the container 4to a substantial depth and vthe container assumes a position with itsgopen the popping oil Ahas been introduced into the container 4, the platform 6 is lowered to its` initial position and the lled container 4 is removed manually or otherwise and replaced by another container filled with popcorn kernels and to which the popping oil is to be added by a repetition of the cycle just explained.

It is to be understood that the popping oil added to the container lls all of the voids between the kernels K and assumes the level X, vlindicated in Fig. 4, so that .al1 of the kernels are immersed in `and completely covered with the oil. The kernels K are heavier per unit volume than the oil and, therefore, do not float in the oil. After the oil has been added to the container, a conventional metallic cover- 34 having a rubber gasket 35 therein is applied to the open endof the container to form an air-tight seal with thev bead 33.

The consistency of the popping oil is such that, as beforestated, when it is'desired to use the product, one need only "pour the kernels out of the container into the popper and the appropriate amount of oil will accompany the kernels. Thus, the package provided by the present invention contains popcorn kernels in a condition ready-to-be-popped. Moreover, the kernels are coated with oil at all times to preserve their moisture content and the optimum amount of oil is always present to insure maximum popping volume.

It will be understood that the disclosure is not limited to packaging a specic size of popcorn kernel with a predetermined amount of oil, inasmuch as various sizes of kernels can be packed with the requisite amount of popping oil, as desired.

It will also be understood that the proportions of the popcorn and popping oil, and the proportions and method of mixing and blending the oils may be varied slightly from the limits set forth herein without departing from the principles of the invention, and that fats or oils other than the oils specifically named may be substituted in carrying out the packaging process. It will also be understood that any suitable apparatus may be employed for effecting the introduction of the popcorn kernels into the container, and that changes in the details of construction and in the arrangement of the apparatus disclosed herein for effecting the subsequent addition of the popping oil to the container may be made without departing from the principles of the invention or the scope of the annexed claims.

I claim:

1. A food package comprising: a container; a mass of popcorn kernels in said container and substantially filling said container; and popping keriiels 'being offsubstantial'lyhuniformfsize such: Lthat they" willpassllthrogh fa, 2%4 .of aninch mesh Screen "ibut inotthrough "ia: l`inch T mesh YJSEPI-IWI. MARTIN.

References Cited in the le'fthiypatet iUNITTEB STATES 'PATENTS 'Name 'Date 'z v15011064 i Roberts.1- .--1Mar 22g-1898 and Related MaterialsQ-Reinhold Pub. "Co.,`300 

1. A FOOD PACKAGE COMPRISING: A CONTAINER; A MASS OF POPCORN KERNELS IN SAID CONTAINER AND SUBSTANTIALLY FILLING SAID CONTAINER; AND POPPING OIL IN SAID CONTAINER FILLING THE VOIDS BETWEEN SAID POPCORN KERNELS, WHEREBY THE POPCORN KERNELS AND POPPING OIL CAN BE SIMULTANEOUSLY POURED FROM THE CONTAINER AS A COHESIVE FLOWABLE MASS. 